Method for making high lubricity abradable material and abradable coating

ABSTRACT

An abradable powder composition is includes a metal component, a lubricant component, and a polymer component. A portion of the metal component is wrapped in the lubricant component to achieve high lubricity and abradability. The abradable powder composition can be used to form an abradable seal coating provided for use in a turbo machinery having a housing and a wheel having multiple blades. The housing houses the wheel which rotates therein. The seal coating is formed on the inner walls of housing adjacent where the wheel blades pass during their rotation. When the wheel is rotated such that, the blades contact the seal coating, it is abraded to form a close fit gap. The abradable seal coating preferably does not produce significant wear of the blade tips or transfer abradable material significantly to the blade tips upon being abraded.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. application Ser.No. 17/007,820 filed Aug. 31, 2020.

TECHNICAL FIELD

The present disclosure relates generally to composite abradable powdermaterials with high lubricity. More specifically, this disclosurerelates to composite abradable powder materials that can be applied ascoatings to form abradable seals for turbo machineries.

BACKGROUND

Materials which abrade readily in a controlled fashion are used in anumber of applications, including as abradable seals for clearancecontrol. As will be appreciated by those skilled in the art, contactbetween a moving part and a fixed abradable seal causes the abradablematerial to erode in a configuration which closely mates with andconforms to the moving part at the region of contact so that the sealtakes on a geometry which precisely fits the moving part, i.e., a closeclearance gap. This effectively forms a seal having an extremely closetolerance.

One particular application of abradable seals is their use in axial orcentrifugal flow turbo machineries, or turbines. Such turbines typicallyhave a rotating compressor or rotor that includes a plurality of bladesattached to a shaft which is mounted in a housing. In operation, theshaft and blades rotate inside the housing. As will be appreciated bythose skilled in the art, it is important to reduce back flow inturbines to increase and/or maximize turbine efficiency. This isachieved by reducing and/or minimizing the clearance between the bladetips and the inner wall of the housing. Ideally, the housing would bemanufactured with the minimum clearance between its inner wall and theblade tips. However, there are practical reasons that this is not done.For example, as the turbine blades rotate, they expand somewhat due tothe heat that is generated. Thus, during operation the blades couldcontacting the housing wall due to this thermal expansion. Because thesecomponents are typically made out of hard materials such as metals, andthe turbine components rotate with a high frequency, contact between thevarious components during operation can result in damage to the blades.To avoid such damage to the blades as a result of contact with thehousing, the housing is often manufactured with a greater clearancebetween its inner wall and the blade tips. However, there is still adesire to maximize turbine efficiency by minimizing the clearance.

Thus, to increase and/or maximize turbine efficiency without the minimumclearance between the housing and the blades, the inner surface of thehousing is coated with an abradable material to serve as a pseudo-innerwall comprised of an abradable coating. The abradable coating isproduced such that the initial placement of the shaft and blade assemblyin the housing results in the blade tips being arranged as close aspossible to the abradable coating. As the turbine blades rotate andexpand due to heat, the rotating blade tips contact the abradablematerial and carve precisely defined grooves in the coating withoutcontacting the housing itself. It will be understood that these groovesprovide the clearance necessary to permit the blades to rotate atelevated temperatures and thus provide a custom-fitted seal for theturbo machinery.

In other gas turbines, the initial clearance is somewhat greater and theabradable coating is intended to protect the housing and blade tipsagainst wear during transient conditions (e.g., power surges).

In order for the turbine blades to cut grooves in the abradable coating,the material from which the coating is formed preferably abradesrelatively easily without wearing down the blade tips. Additionally, theabradable seal material is preferably not transferred to the blade tipsupon abrading. However, the coating should have a high enough structuralintegrity to maintain its shape but for the abraded material. Thisrequires a careful balance of materials in the coatings. Furthermore, inthe environments in which the abradable coating is used, it shouldexhibit good resistance against particle erosion and other degradationat elevated temperatures. As known by those skilled in the art, however,these desirable characteristics have been difficult to obtain.

Therefore, it would be desirable to provide a composite material whichabrades readily without producing significant wear of rotating partswhile otherwise maintaining its structural integrity in harshenvironments, such as in gas turbines. It would also be desirable toprovide such a material which can be fabricated using conventionalthermal spray techniques, such as air plasma or flame spray techniques.It would still further be desirable to provide such a coating whichcould be used to form abradable seals in relatively low-temperatureenvironments wherein the seal material does not adhere to rotatingparts.

The present disclosure achieves these goals by providing compositepowder materials which contain a metal component, a lubricant component,and a polyester component.

SUMMARY

In one aspect, a composite abradable powder composition is providedwhich includes a metal component, a lubricant component, and a polymercomponent. A portion of the metal component is wrapped in the lubricantcomponent.

In another aspect, an abradable seal coating is provided for use in aturbo machinery having a housing and a wheel having multiple blades. Thehousing houses the wheel which rotates therein. The seal coating isformed on the inner walls of housing adjacent where the wheel bladespass during their rotation. When the wheel is rotated such that, theblades contact the seal coating, it is abraded to form a close fit gap.The abradable seal coating preferably does not produce significant wearof the blade tips or transfer significantly to the blade tips upon beingabraded. The abradable seal coating is formed from the abradable coatingmaterial above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic representation of a composite powdermaterial for high lubricity and abradability in accordance with thepresent disclosure.

FIG. 2 is a perspective view of a turbocharger compressor housing withan abradable seal coating formed on inner surface of thereof inaccordance with the present disclosure.

DETAILED DESCRIPTION

In a first preferred embodiment, an abradable powder composition isprovided that includes a metal component, a lubricant component, and apolyester component, wherein a portion of the metal component is wrappedin the lubricant component. That is, some, but not all, of the metal iswrapped in the lubricant. The composition thus generally includes threecomponents: polyester, lubricant-wrapped metal, and unwrapped metal.This lubricant-wrapped metal component can be produced using amechanical milling, chemical deposition, chemical vapor deposition(CVD), or physical vapor deposition (PVD) process.

The metal component can be a metal or a metal alloy. Preferred metalcomponents include aluminum or an aluminum alloy, such as aluminumsilicon alloy (silumin) or aluminum bronze alloy. The metal component inthe powder composition is preferably in the form of metal particles, andare preferably aluminum particles or aluminum alloy particles. Inaddition to aluminum and silicon, silumin can also contain other metals,such as magnesium and copper. Similarly, in addition to aluminum andcopper, aluminum bronze can also contain other metals, such as iron,nickel, cobalt, manganese, silicon, tin, and zinc. Other metal alloyscan also include iron, nickel, cobalt, manganese, silicon, tin, or zinc.The metal components are preferably present as at least 50 by weight ofthe total powder composition.

The lubricant component can be any suitable dry lubricant. Preferablylubricant materials include boron nitride such as hexagonal boronnitride, molybdenum disulfide, graphite, tungsten disulfide, ormolybdenum diselenide. Mixtures of multiple lubricant materials,including but not limited to the preferred lubricants above, can be usedas the lubricant component. The lubricant component is preferablypresent as at least 1 wt. % of the total powder composition.

The polymer component can be any suitable polymer, include copolymers.Preferred polymers include polyester. The preferred polyester ispoly(oxy-1,4-phenylenecarbonyl). The polymer component is preferablypresent as at least 5 wt. % of the total powder composition.

To provide advantageous properties for coatings produced therefrom, thepowder composition is preferably made up of a portion of the metalcomponent wrapped in the lubricant component, the remaining portion ofthe metal component unwrapped, and the polyester component. Preferably,the powder composition includes 50 to 94 wt. % of the metal component, 1to 10 wt. % of the lubricant component, and 5 to 40 wt. % of the polymercomponent. Preferably, at least 20% by weight of the metal component iswrapped in the lubricant component. More preferably, at least 20% byweight of the metal component is wrapped with lubricant and has lessthan 30% by surface of exposed metal component.

A coating produced from the powder composition described above hasnumerous properties that are advantageous to use as an abradable sealcoating. For example, the hardness is relatively low of the powdermaterial and thus abradable seals produced therefrom, which preventssignificant wear of a moving component that engages seals, such as theblade tips of a turbo machinery. By preventing significant wear, it ismeant that the moving component is not damaged in a way that materiallyaffects its performance or performance lifetime. Weak bonding betweenthe individual lubricant-wrapped metal component particles contributesto the relatively low hardness. The powder material and abradable sealcoatings produced therefrom also have good lubricity, which also helpsto prevent significant wear of the moving component and reduces materialto transfer to the moving component. The powder material and abradableseal coatings produced therefrom also have a good balance betweencoating integrity and abradability, resulting in the seal abradingeasily when contacted with the moving component while at the same timebeing held together with strong enough bonds such that the sealmaintains its structure, particularly in harsh environments. The balancebetween coating integrity and abradability is achieved by the bondingbetween the materials. The polymer material particularly contributes tothe abradability while the unwrapped metal component contributes to thecoating integrity.

To form the powder material, particles of the metal component arewrapped in a phase of the lubricant component using a mechanical orchemical process in a first step. The lubricant phase/film on metal orits alloy particles will provide a non-stick or weak bonding between theparticles, and also provide lubricity property into the material. Thefirst property will aim to improve abradable property, and the secondproperty to lubricity. In a second step, additional particles of themetal component are mixed with the lubricant-wrapped metal componentparticles to create a mixture of wrapped metal and unwrapped metal. Thismixture of material will ensure the resultant coating has goodmechanical properties, abradable properties and coating integrity. In athird step, to further improve abradability, particles of the polymercomponent are added to the mixture of lubricant-wrapped metal particlesand unwrapped metal particles by a blending process to produce thepowder composition. In a fourth step, the powder can be sprayed withconventional thermal spray techniques, such as by air plasma or flame,onto a surface to produce a coating thereon.

An example of a powder composition 1 is shown schematically in FIG. 1that includes a metal component 10, a lubricant component 20, and apolymer component 30. A portion of the metal component 10 is formed asunwrapped metal component 10 a, whereas the remainder of the metalcomponent 10 is wrapped with lubricant 20 to form wrapped metalcomponent 10 b.

The powder material is suitable to be used as an abradable seal coatingfor maximizing the efficiency of an axial or centrifugal turbomachinery. FIG. 2 depicts an example turbo machinery, specifically aturbocharger, 100 that includes a housing 101 having inner walls thatdefine an open interior 102 designed to contain a wheel having blades(not pictured) that rotates therein. An abradable seal coating 103 isformed on the inner walls of the housing 101. The abradable seal coatingis prepared from the powder composition 1 discussed above. The powdercomposition 1 is applied as a coating to the inner walls of the housing101 adjacent where the wheel blades pass during their rotation to formthe abradable seal coating 103. Conventional thermal spray techniquescan be used to produce the coating in the turbo machinery housing toform the abradable seal coating. Air plasma or flame spray are examplesof spray techniques to produce the coatings. Upon rotation, the bladesof the wheel contact the abradable seal coating 103 such that it isabraded to form a seal having close fit gap. The close fit gap reducesbackflow in the turbo machinery.

The abradable seal coating 103 preferably does not produce significantwear of the blade tips. To achieve this, the hardness of the abradableseal coating 103 on the R15Y scale is preferably less than 70, morepreferably less than 60, and most preferably less than 50. Preferably, aminimal portion of the abradable seal that abrades adheres to the bladetips upon abrading. Preferably 3%, more preferably 2%, and even morepreferably 1% of the abraded portion of the seal adheres to the bladetips after it is abraded.

When ranges are expressed herein, it is to be appreciated that otherembodiments include any subranges and values encompassed therein. Forexample, the range of 10 to 20% encompasses 10 to 15%, 12 to 17%, 13 to20%, and so forth.

1. A method of making an abradable coating, comprising the steps of:providing a powder composition comprising particles of a metalcomponent, a lubricant component, and particles of a polymer componentsuch that the metal component is at least 50% by weight of the powdercomposition and the lubricant component is 1% to 10% by weight of thepowder composition, and such that each particle within a first subset ofthe particles of the metal component of the powder composition iswrapped in the lubricant component and each particle within a secondsubset of the particles of the metal component of the powder compositionis free of the lubricant component; and thermal spraying the powdercomposition onto a substrate.
 2. A method of making a seal for turbomachinery having a housing with inner walls that define an open interiorsuitable for containing a rotatable component, the method comprising thesteps of: providing a powder composition comprising particles of a metalcomponent, a lubricant component, and particles of a polymer componentsuch that the metal component is at least 50% by weight of the powdercomposition and the lubricant component is 1% to 10% by weight of thepowder composition, and such that each particle within a first subset ofthe particles of the metal component of the powder composition iswrapped in the lubricant component and each particle within a secondsubset of the particles of the metal component of the powder compositionis free of the lubricant component; and spraying the powder compositiononto at least a portion of the inner walls of the housing of the turbomachinery to form an abradable coating thereon.
 3. The method accordingto claim 2, wherein the turbo machinery is a turbocharger.
 4. A coatinghaving a composition comprising a metal component, a lubricantcomponent, and a polymer component, the metal component being at least50% by weight of the composition and the lubricant component being 1% to10% by weight of the composition, and the coating being abradable. 5.The coating according to claim 4, wherein the coating has a hardnessR15Y of less than
 70. 6. The coating according to claim 4, wherein thecoating has a hardness R15Y of less than
 60. 7. The coating according toclaim 4, wherein the coating has a hardness R15Y of less than
 50. 8. Thecoating according to claim 4, wherein the metal component is aluminum oran aluminum alloy.
 9. The coating according to claim 4, wherein themetal component is an aluminum alloy comprising aluminum and silicon orcopper.
 10. The coating according to claim 4, wherein the metalcomponent is a metal or an alloy comprising iron, nickel, cobalt,manganese, silicon, tin or zinc.
 11. The coating according to claim 4,wherein the lubricant component comprises hexagonal boron nitride,molybdenum disulfide, graphite, tungsten disulfide, molybdenumdiselenide, or mixtures thereof.
 12. The coating according to claim 4,wherein the polymer component is 5 to 40% by weight of the composition.13. The coating according to claim 4, wherein the polymer componentcomprises a polyester.
 14. The coating according to claim 4, wherein thepolyester comprises poly(oxy-1,4-phenylenecarbonyl).
 15. The coatingaccording to claim 4, wherein the coating is a thermal sprayed coatingof a powder composition that comprises particles of the metal component,the lubricant component, and particles of the polymer component suchthat the metal component is at least 50% by weight of the powdercomposition and the lubricant component is 1% to 10% by weight of thepowder composition, and such that each particle within a first subset ofthe particles of the metal component of the powder composition iswrapped in the lubricant component and each particle within a secondsubset of the particles of the metal component of the powder compositionis free of the lubricant component.
 16. A turbo machinery, comprising: ahousing having inner walls that define an open interior suitable forcontaining a rotatable component, and a seal formed from the coating ofclaim 4 on at least a portion of the inner walls of the housing.
 17. Theturbo machinery according to claim 16, wherein the seal is abradablesuch that a portion of the seal abrades upon contact with the rotatablecomponent while the rotatable component is rotating and such that lessthan 3% of the portion of the seal that abrades adheres to the rotatablecomponent after the abrasion.
 18. The turbo machinery according to claim17, wherein less than 2% of the portion of the seal that abrades adheresto the rotatable component after the abrasion.
 19. The turbo machineryaccording to claim 17, wherein less than 1% of the portion of the sealthat abrades adheres to the rotatable component after the abrasion. 20.The turbo machinery according to claim 16, wherein the turbo machineryis a turbocharger.